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Originally Posted by SeanC
1. Did you rebuild the strut yourself? If so, did you make sure that the correct stud bolt was flush with the positioning pin that goes into the spring holder groove?
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Yes, I rebuilt the strut myself. There was no locating stud on either the OE shock nor the KYB replacement, nor the Bilstein replacement, IIRC. Yes, that's right - I've actually rebuilt it twice trying to find this rattle. The OE and KYB have a convex bottom which matches the profile of the strut holder, whereas the Bilstein does not. There's no movement of the shock in the strut holder.
Quote:
Originally Posted by SeanC
2. Did you inspect the functioning of the brake caliper? Is it completely free of rust, free to move, and the boot is intact?
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Yes, yes, yes, and yes. There is a very minor amount of play between the pads and the caliper carrier which I'm going to compare to the other side, and maybe swap pads from side to side. I replaced the pads about a year ago with Pagid black pads; a little dusty but certainly good quality. I always wire brush and clean the caliper carrier contact points when I change pads.
Now that I've been driving the vehicle for about a week after replacing the front drive shaft, it seems like the clunk and rattle are reduced by about 50%, but it's really hard to tell as the roads are clearing of snow and aren't quite as rough.